Internal combustion engine ignition distributor cap and coil assembly

ABSTRACT

An internal combustion engine ignition distributor cap and coil assembly. An intermediate member of insulating material supports a plurality of elongated electrical terminals arranged in a circular pattern, one for each cylinder of the engine, and an equal number of elongated conductors, each of which is connected to one end of a corresponding one of the elongated terminals and extends substantially normal to the axis of the circular pattern of terminals. An ignition coil housing member, within which the ignition coil windings are enclosed, is secured to a cap member with the intermediate member disposed therebetween and the free end of each terminal extending through a corresponding terminal accommodating opening through the closed end portion of the cap member to provide a three-section assembly.

[ 1 Feb. 1,1972

United States Hetzler et al.

INTERNAL COMBUSTION ENGINE 1,317,357 9/1919Dorsey.........'..................l23/148DX IGNITION DISTRIBUTOR CAP ANDCOIL ASSEMBLY Primary Examiner-Laurence M. Goodridge Attorney-Eugene W.Christen, Creighton R. Meland and Richard G. Stahr ABSTRACT An internalcombustion engine ignition distributor cap and coil assembly. Anintermediate member of insulating material supports a plurality ofelongated electrical terminals arranged in a circular pattern, one foreach cylinder of the engine, and an equal number of elongatedconductors, each of which is connected to one end of a corresponding oneof the elongated terminals and extends substantially normal to the axisof the circular pattern of terminals. An ignition coil housing member,within which the ignition coil windings are enclosed, is secured to acap member with the intermediate member disposed therebetween and thefree end of each terminal extending through a corresponding terminalaccommodating opening through the closed end portion of the cap memberto provide a three-section assembly.

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SHEET 2 BF 2 INVENTORS ATTORNEY INTERNAL COMBUSTION ENGINE IGNITIONDISTRIBUTOR CAP AND COIL ASSEMBLY This invention is directed to internalcombustion engine ignition distributor caps and, more specifically, toan internal combustion engine ignition distributor cap and coilassembly.

With current production automobiles, the ignition distributor and theignition coil are separate units, the ignition coil being mountedseparately from the distributor. Furthermore, with current productionmodels, the ignition cables extending between the distributor and therespective spark plugs of the engine are taken from terminals arrangedin a circular pattern about the top of the ignition distributor cap.This arrangement necessitates separate mounting facilities for theignition coil and greatly adds to the height of the ignitiondistributor. ,To reduce the facilities required to install the ignitionsystem and to reduce the overall height of the distributor, an internalcombustion engine ignition distributor cap and coil assembly in whichthe ignition cables extend horizontally therefrom is desirable.

It is, therefore, an object of this invention to provide an improvedinternal combustion engine ignition distributor cap.

It is another object of this invention to provide an improved internalcombustion engine ignition distributor cap and coil assembly.

It is a further object of this invention to provide an improved internalcombustion engine ignition distributor cap and coil assembly wherein theignition cables extend horizontally therefrom to reduce the overallheight of the ignition dis tributor.

In accordance with this invention, an internal combustion engineignition distributor cap and coil assembly is provided wherein anignition coil housing member is secured to a distributor cap member withan intermediate member of an insulating material, which supports aplurality of elongated terminals arranged in a circular patternextending through corresponding terminaI-accommodating openings in theclosed end portion of the cap member and an equal number of elongatedelectrical conductors each connected to one end of a corresponding oneof the terminals and extending substantially normal to the axis of thecircular pattern of terminals, disposed therebetween to provide athree-section ignition distributor cap and coil assembly.

For a better understanding of the present invention, together withadditional objects, advantages and features thereof, reference is madeto the following description and accompanying drawings in which:

FIG. 1 is a section view of the internal combustion engine ignitiondistributor cap and coil assembly of this invention mounted on anignition distributor;

FIG. 2 is a top plan view of the internal combustion engine ignitiondistributor cap and coil assembly of this invention;

FIG. 3 is a section view of FIG. 1 taken along line 3-3 and looking inthe direction of the arrows;

FIG. 4 is a section view of FIG. 3 taken along line 4-4 and looking inthe direction of the arrows; and

FIG. 5 is a section view of FIG. 1 taken along line 5-5 and looking inthe direction of the arrows.

Throughout the figures of the drawings, like elements have been assignedlike characters of reference.

The internal combustion engine ignition distributor cap and coilassembly of this invention comprises an ignition coil housing member ofplastic material within which the primary and secondary windings of theignition coil 8 are enclosed; an intermediate member of electricalinsulating material supporting a plurality of elongated terminals, 21through 28, of electrically conductive material arranged in circularpattern and an equal number of elongated electrical conductors, 31through 38, each one of which is electrically connected to one end of acorresponding one of the elongated terminals and extends substantiallynormal to the axisof the circular pattern of terminals; a cap member ofelectrical insulating material having a sidewall portion 41 and anintegral end enclosing portion 42 having a terminal accommodatingopening therethrough corresponding to each one of the elongatedelectrical terminals supported by intermediate member 20 and, a methodfor securely attaching the ignition coil housing member 10 to the capmember 40 with the intermediate member 20 disposed therebetween and eachelongated electrical terminal supported thereby extending through thecorresponding one of the terminal-accommodating openings through the endenclosing portion 42 of cap member 40 to provide a three-sectionassembly.

The primary and secondary windings of ignition coil 8 may, if desired,be precast in or impregnated by an epoxy resin which is cured to providea hardened assembly. After the curing operation, the coil magnetic ironmay be assembled to the coils to complete the ignition coil.

The ignition coil housing member I0 may be of two-piece constructionmade up of a top section 11 and a base or enclosing section 12 which maybe fabricated of any suitable plastic material possessing satisfactoryelectrical insulation and mechanical impact characteristics such as thephenolics and alkyds. The top section 11 may be provided with acircumferential lip 14 of a diameter which will accommodate base section12 in a press fit relationship. If desired, the volume enclosed by topsection II and base section 12 and surrounding ignition coil 8 may befilled with a suitable potting compound, such as polyurethane, throughopenings 15 to provide a unitary ignition coil assembly.

The intermediate member 20 may be made of a resilient electricalinsulating material such as polychloroprene and of two-piececonstruction made up of top and bottom sections, the bottom sectionbeing illustrated in FIG. 3. A top section of the same material andshape which is congruent to that of FIG. 3 may then be cemented or gluedto the bottom section to provide a unitary assembly.

The intermediate member 20 supports a plurality of elongated terminalsof electrically conductive material which are referenced in the drawingsby the numerals 21 through 28', inclusive. These elongated electricalterminals are arranged in a circular pattern as is best seen in FIG. 3and correspond in number to the number of cylinders of the engine withwhich the ignition distributor cap and coil assembly of this inventionis being used. For purposes of this specification, it will be assumedthat the ignition distributor cap and coil assembly of this invention isbeing used with an eight-cylinder engine; consequently, eight elongatedterminals supported by intermediate member 20 are indicated in thedrawings.

The intermediate member 20 also supports an equal number of elongatedelectrical conductors or ignition cables which electrically interconnecteach elongated terminal of the intermediate member 20 with acorresponding spark plug of the engine with which the ignitiondistributor cap and coil assembly is being used and are referenced inthe drawing by numerals 31 through 38, inclusive. Each elongatedconductor is connected to one end of a corresponding one of theelongated terminals and extends substantially normal to the axis of thecircular pattern of terminals, as is best seen in FIGS. 3 and 4.

When the ignition distributor cap and ignition coil assembly of thisinvention is used with V-type engines, the elongated conductors may besubstantially parallel with one half extending in a direction oppositethe other half as best seen in FIG. 3. With this arrangement one half ofthe conductors are connected to respective spark plugs of one bank ofengine cylinders and the other half are connected to the spark plugs ofthe other bank of engine cylinders. Consequently, crossed ignitioncables between engine cylinder banks are eliminated.

To facilitate the interconnection between each elongated terminal andthe corresponding elongated electrical conductor, each elongatedterminal may have a reduced portion of a rectangular cross section ateach end of a dimension which will snugly accommodate the eye of theelectrical connector affixed to the end of each elongated conductor, asis best seen in FIG. 3. This reduced portion may be provided on bothends of each elongated terminal for the purpose of facilitatingassembly.

The cap member 40 may be molded of any suitable plastic materialpossessing satisfactory electrical insulation and mechanical impactcharacteristics such as the phenolics and alkyds. The cap member 40 mayhave a sidewall portion 41 which may be of circular cross section or anyother accommodating shape, and an integral end enclosing portion 42.However, cap member 40 may be of a two-piece construction withoutdeparting from the spirit of the invention.

The end enclosing portion 42 of cap member 40 has a terminalaccommodating opening therethrough corresponding to each one of theelongated electrical terminals supported by intermediate member 20, asis best seen in FIGS. 4 and 5. In FIG. 4, it may be seen that elongatedterminal 27 extends through a corresponding terminal accommodatingopening 47 through the end enclosing portion 42 of cap member 40. Theremaining elongated terminals, of course, extend through similarcorresponding terminal accommodating openings through end enclosingportion 42 of cap 40, as is best seen in FIG. 5.

The ignition coil housing member may be securely attached to cap member40 with the intermediate member 20 disposed therebetween and eachelongated electrical terminal supported thereby extending through thecorresponding one of the terminal accommodating openings through the endenclosing portion 42 of cap member 40 by screws or bolts 48 and 49 toprovide a three-section assembly. To facilitate assembly, cap member 40may be supplied with metallic inserts having an internally threaded borewhich will accommodate the threads of screws or bolts 48 and 49. It isto be specifically understood, however, that any other suitable methodof attaching ignition coil housing member 10 to cap member 40 withintermediate member 20 disposed therebetween may be employed withoutdeparting from the spirit of the invention.

Cap member 40 is arranged to be telescoped over the rotor 60 of anignition distributor having a movable terminal 61 secured thereto. Asthe rotor 60 is revolved by the engine with shaft 62 in a manner wellknown in the automotive art, movable terminal 61 passes closely adjacentthat end of each of elongated terminals 21 through 28 which extendsthrough the corresponding terminal accommodating opening in the endenclosing portion 42 of cap 40, as is best seen in FIG. 1. The capmember 40 may be securely attached to the distributor bowl 63 by screwsor bolts 64 and 65, as is seen in FIGS. 1 and 2.

To facilitate external electrical connections to the primary andsecondary windings of ignition coil 20, external terminals such as 70may be provided as shown in FIG. 1.

Although the ignition distributor cap and coil assembly of thisinvention is indicated in FIG. 1 to be used with a magnetic-typedistributor, it is to be specifically understood that this assembly isequally satisfactory for use with a breakercontact-type distributor.

The assembly of this invention reduces the number of electricalconnections from 18 to nine with an eight cylinder engme.

While a preferred embodiment of the present invention has been shown anddescribed, it will be obvious to those skilled in the art that variousmodifications and substitutions may be made without departing from thespirit of the invention which is to be limited only within the scope ofthe appended claims.

We claim: 1. An internal combustion engine ignition distributor cap andcoil assembly comprising:

an ignition coil housing member of plastic material within which theprimary and secondary windings of an ignition coil are enclosed, anintermediate member of electrical insulating material supporting aplurality of elongated terminals of electrically conductive materialarranged in a circular pattern and an equal number of elongatedelectrical conductors, each one of which is electrically connected toone end of a corresponding one of said elongated terminals and extendssubstantially normal to the axis of said circular pattern of terminals,a cap member of electrical insulating material having a sidewall portionand an integral end enclosing portion having a terminal accommodatingopening therethrough corresponding to each one of said elongatedelectrical terminals supported by said intermediate member, and

means for securely attaching said ignition coil housing member to saidcap member with said intermediate member disposed therebetween and eachsaid elongated electrical terminal supported thereby extending throughthe corresponding one of said terminal accommodating openings throughsaid end enclosing portion of said cap member to provide a three-sectionassembly.

2. An internal combustion engine ignition distributor cap and coilassembly comprising:

an ignition coil housing member of plastic material within which theprimary and secondary windings of an ignition coil are enclosed and atleast partially encapsulated in a potting material,

an intermediate member of resilient electrical insulating materialsupporting a plurality of elongated terminals of electrically conductivematerial arranged in a circular pattern and an equal number of elongatedelectrical conductors, each one of which is electrically connected toone end of a corresponding one of said elongated terminals and extendssubstantially normal to the axis of said circular pattern of terminals,

a molded cap member of electrical insulating material having a sidewallportion and an integral end enclosing portion having aterminal-accommodating opening therethrough corresponding to each one ofsaid elongated electrical terminals supported by said intermediatemember, and

means for securely attaching said ignition coil housing member to saidcap member with said intermediate member disposed therebetween and eachsaid elongated electrical terminal supported thereby extending throughthe corresponding one of said terminal-accommodating openings throughsaid end enclosing portion of said cap member to provide a three-sectionassembly.

1. An internal combustion engine ignition distributor cap and coilassembly comprising: an ignition coil housing member of plastic materialwithin which the primary and secondary windings of an ignition coil areenclosed, an intermediate member of electrical insulating materialsupporting a plurality of elongated terminals of electrically conductivematerial arranged in a circular pattern and an equal number of elongatedelectrical conductors, each one of which is electrically connected toone end of a corresponding one of said elongated terminals and extendssubstantially normal to the axis of said circular pattern of terminals,a cap member of electrical insulating material having a sidewall portionand an integral end enclosing portion having a terminal accommodatingopening therethrough corresponding to each one of said elongatedelectrical terminals supported by said intermediate member, and meansfor securely attaching said ignition coil housing member to said capmember with said intermediate member disposed therebetween and each saidelongated electrical terminal supported thereby extending through thecorresponding one of said terminal accommodating openings through saidend enclosing portion of said cap member to provide a three-sectionassembly.
 2. An internal combustion engine ignition distributor cap andcoil assembly comprising: an ignition coil housing member of plasticmaterial within which the primary and secondary windings of an ignitioncoil are enclosed and at least partially encapsulated in a pottingmaterial, an intermediate member of resilient electrical insulatingmaterial supporting a plurality of elongated terminals of electricallyconductive material arranged in a circular pattern and an equal numberof elongated electrical conductors, each one of which is electricallyconnected to one end of a corresponding one of said elongated terminalsand extends substantially normal to the axis of said circular pattern ofterminals, a molded cap member of electrical insulating material havinga sidewall portion and an integral end enclosing portion having aterminal-accommodating opening therethrough corresponding to each one ofsaid elongated electrical terminals supported by said intermediatemember, and means for securely attaching said ignition coil housingmember to said cap member with said intermediate member disposedtherebetween and each said elongated electrical terminal supportedthereby extending through the corresponding one of saidterminal-accommodating openings through said end enclosing portion ofsaid cap member to provide a three-section assembly.